Brushless DC motors controlled using conventional 120° electronic commutation schemes exhibit stator current discontinuities during phase commutation, resulting in torque ripple that leads to flow fluctuations, noise, and vibration in aqua-pumping applications. This paper proposes a Hall-sensored 180° electronic commutation scheme implemented as a simplified six-step logic using Boolean Disjunctive Normal Form (DNF), enabling extended-angle conduction while avoiding the implementation complexity of zero-crossing detection (every 60° electrical) required in sensorless methods. A new multi-stage off-grid solar photovoltaic array (SPA)-powered pumping system assisted by twin-battery storage is presented, incorporating a two-phase direct-coupled interleaved boost (2P-DCIB) converter to raise the SPA voltage to 310 V at the DC link, achieving a voltage gain of 2 at a duty cycle of 0.327. To manage dynamic irradiance conditions, an ANN-based MPPT employing alternative inputs (error Er and change in error ΔEr) is formulated to accelerate tracking, eliminate the need for dataloggers required by conventional-input ANN MPPTs, and remove the complex manual tuning associated with fuzzy rule-based approaches. This work further introduces a Twin Battery Storage Control (TBSC) scheme that coordinates the master and secondary battery stacks through parallel-active bidirectional converters. The TBSC enforces state-of-charge limits (15 % ≤ SoC ≤ 95 %), corresponding to an effective 80 % depth of discharge, and provides protection against overcharging and over-discharging while simultaneously addressing DC-link voltage deviations typically observed with conventional controllers during protective actions. The scheme stabilizes the DC-link voltage with near-zero deviation, ensuring rated motor operation even under extreme conditions. The effectiveness of the proposed control strategies in suppressing peak-to-peak and RMS torque ripple and maintaining tight DC-link voltage regulation is demonstrated through MATLAB/Simulink simulations and validated using real-time digital simulations on the OPAL-RT OP4510 platform. Comparative evaluation against existing commutation and MPPT techniques confirms the performance improvements achieved by the proposed system.
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